Manufacturing Management ISA 95

1. 1
Manufacturing Operations
Management

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Objectives
• Review the ISA 95 standards and how they are being
used in companies like Eli Lilly & Company for shop
floor to top floor integration
– The standards provide a formal model for exchanged data
between business systems and manufacturing systems
– The models also include a definition of Manufacturing
Operations Management, the activities on the shop floor that
take production schedules and perform the actual work
required to manufacture products
• The Manufacturing Operations Management models
are currently being used in the development of
multiple new manufacturing facilities

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Manufacturing in the Supply Chain
• “Make” is a significant part of the supply chain and
collaborative manufacturing, but is often the last
element to be actually integrated
– Collaboration in “Make” is usually not a “Low Hanging Fruit”
– But can offer very high ROI for high volume, or high cost
products
• However, Business IT and Manufacturing IT
organizations are often at odds as they try to
collaborate
– They have different goals and different success criteria
– They use the same terms for different elements and different
terms for the same elements

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Collaborative Manufacturing Help
• Fortunately there are multiple standards in
place to help integrating business systems
with manufacturing systems.
– The ISA 95 Enterprise/Control System Integration
standards, also an IEC/ISO standard
– XML Schemas standards for collaborative
manufacturing from the World Batch Forum
• Will show how they are being applied to the
development of manufacturing systems
roadmap

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Different Points of View
• Business Systems
– Time Horizons
• Long-term view
– Model detail
• Linear route structures
– Control emphasis
• Product cost and overall
profitability
– Modeling criteria:
• Accounting reference
points
• Has inventory value
changed significantly? If
not, don’t model
separately
– View from the boardroom
• Manufacturing Systems
– Time Horizons
• Real-time view
– Model detail
• Complex routes with
rework paths
– Control emphasis
• Physical movement &
accountability
– Modeling criteria:
• material movement
reference points
• Does product stop
moving? If not, don’t
model separately
– View from the workcenter

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Philosophical Orientation
• Enterprise Management systems:
–How much is my stuff worth?
• Manufacturing Operations Systems:
–Where is my stuff?

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ISA 95 Provides Direction
• The ANSI/ISA 95.00.01 “Enterprise - Control
System Integration - Part 1: Models and
Terminology”
– Also Draft International Standard ISO/IEC 62264-1
• ANSI/ISA 95.00.02 “Enterprise - Control
System Integration - Part 2: Object Attributes”
• Draft ISA 95.00.03 “Enterprise - Control
System Integration - Part 3: Activity Models of
Manufacturing Operations Management”

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Business Planning & Logistics
Plant Production Scheduling,
Operational Management, etc
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Batch
Control
Discrete
Control
Continuous
Control
Level 4
Level 3
Levels
2,1,0
ISA95.01 Levels
Interface addressed
in the ISA 95.01 and
ISA 95.02 standard
Area addressed
in the ISA 95.03
standard

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Business Planning & Logistics
Plant Production Scheduling,
Operational Management, etc
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Business Logistics Management (ERP)
9
Interface addressed
in the ISA 95.01 and
ISA 95.02 standard
Area addressed
in the ISA 95.03
standard
Batch
Control
Discrete
Control
Continuous
Control
Level 4
Level 3
Levels
2,1,0
ISA95.01 Levels
Manufacturing Operations Management (MES)

10. 10
ISA 95 Part 1 and Part 2
Exchanged Information
Information that crosses the boundary between
business systems and manufacturing systems

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Exchanged Information Categories
Enterprise Information
Plant Production Scheduling,
Operational Management, etc
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc
Product
Definition
Information
(How to make
a product)
Production
Capability
Information
(What is
available
for use)
Production
Schedule
(What to
make and
use)
Production
Performance
(What was
made and
used)

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4x4 Object Models
• Four categories of resources
– Personnel
– Equipment
– Material (and Energy)
– Process Segments
• Four Process, Product, & Production Models
– Capability & Capacity Definition
– Product Definition
– Production Schedule
– Production Performance

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Four Resource Object Models
People
Materials
Equipment
Personnel resources managed for production
Equipment resources managed for production
Material resources managed for production
Process Segments
Business view of production processes

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Capability, Product, Schedule, and
Performance Information
Product
Definitions
Production
Schedule
Production
Performance
What is available for use for production
What is needed to make a product
What to make and resources to use
What was made and resources actually used
Product
Time
Capability/Capacity

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Production Schedule
People
Materials
Equipment
Segments
Production
Schedule
What to make
- Priority and/or dates
- What materials to use
- What equipment to use
- What personnel to use
- Production parameters
(e.g. Color, Options,…)
Per location (Site, Area, …)
Per week, day,
shift, order, …
• Production Schedule
• Production Request
• Segment Request
• Expected Produced Material
• Expected Consumed Material
• Expected Personnel
• Expected Equipment
• Production Parameters
• …

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Production Performance
People
Materials
Equipment
Segments
Production
Performance
What was made
- What material was
actually produced
- What materials were
actually consumed
- Equipment used
- Personnel used
- Production data
(e.g. Purity, density,…)
Per location (Site, Area, …)
Per shift, hour,
end of batch, …
• Production Performance
• Production Response
• Segment Response
• Produced Material Actual
• Consumed Material Actual
• Personnel Actual
• Equipment Actual
• Production Data
• …

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XML Standard for B2M Exchanges
• The World Batch Forum has developed XML
Schemas that map to the ANSI/ISA-95
models
• Defines how to represent the ISA-95
information in XML
– Business To Manufacturing Markup Language
– B2MML
• One schema for each object model
• Formal way to exchange information
– www.wbf.org

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<Material
<MaterialLot>
<ID> W89 </ID>
<Description> A lot of material </Description>
<MaterialDefinitionID> WXE908 </MaterialDefinitionID>
<Location> Tank 1 </Location>
<Quantity
UnitOfMeasure = "KL" > 4500
</Quantity>
<MaterialLotProperty>
<ID> dateTimeProduction </ID>
<Value> 2001-01-06T00:14:23+11:30 </Value>
</MaterialLotProperty>
<MaterialLotProperty>
<ID> Quality Status </ID>
<Value> Good </Value>
</MaterialLotProperty>
</MaterialLot>
</Material>
An XML Example – Material Lot

19. 19
ISA95 Part 3
Activity Models of
Manufacturing Operations
In Development
Expected Release 2004

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INVENTORY
OPERATIONS
INVENTORY
OPERATIONS
MAINTENANCE
OPERATIONS
PRODUCTION
OPERATIONS
QUALITY
ASSURANCE
OPERATIONS
Procurement
(5.0)
Production
Scheduling
(2.0)
Material and
Energy Control
(4.0)
Product
Inventory Control
(7.0)
Product Cost
Accounting
(8.0)
Quality
Assurance
(6.0)
Research
Development
and Engineering
Product
Shipping Admin
(9.0)
Order
Processing
(1.0)
Marketing
& Sales
Production
Control
(3.0)
Maintenance
Management
(10.0)

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ISA 95.03 Manufacturing Operations Functions
Production
resource
management
Production
capability
Analysis
Production
data
collection
Production
execution
Production
dispatching
Production
tracking
Production
performance
Detailed
production
scheduling
Production
schedule
Level 2 Process Control
Product
definition
management
Product
definition
Equipment and Process
Specific Production Rules
Equipment and Process
Specific Data
Operational
Responses
Operational
Commands

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Major
Activities
Within
Manufacturing
Operations
Quality
Operations
Maintenance
Operations
Production
Operations
Level 4
Level 3
Level 2
Management
of Configuration
Management
of Information
Management
of Security
Management
of Documentation
Management
of Compliance
Inventory
Operations
Other Enterprise Activities in
Manufacturing Operations
• Some actives are not specific to manufacturing
• ISA-95.03 lists references to standards in these
areas
Activity detailed
Activity not detailed
Activity outside scope

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Implementations
• Nestle
– Project to use the XML schemas for schedule
exchange
• Arla Foods
– Project to use XML for standard interfaces to
multiple ERP systems and MES systems
• Empersas Polar
– Project to use XML schemas for schedule
exchange
• Eli Lilly
– Projects to use ISA 95 models for manufacturing
operations management architecture

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Building Collaborative Manufacturing
Systems
• Process Used to Develop Solution
Architectures
– Conceptual Topology
– Functional Areas
– Standards and Guidelines
– Standard Applications
– Logical Architecture Design
– Physical Architecture Design

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ISA 95 Control Hierarchy Levels
Level 4
Level 0
Level 1
Level 2
Level 3
Business Logistics
Plant Production Scheduling, Shipping,
Receiving, Inventory, etc
Manufacturing
Operations Management
Dispatching, Detailed Production
Scheduling, Production Tracking, ...
Batch
Production
Control
Discrete
Production
Control
Continuous
Production
Control
ISA – IEC/ISO
Interface
Standards
IEC, OPC, &
OMAC
Interface
Standards
ISA
Functional
Model
The production processes

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What is the PCIMS ?
PCIMS :Process Control Information Management System
Each plant as an individual process area shall consist of an
integrated production control system and the main units of
integrated production system consist of :
UCB : Unit Control Building which is the central location for
controlling , PCB: process control building
RIB which houses all I/O’s and the controllers

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DCS is Distribution Control System
Vendor ,Yokogawa centum CS3000
DCS consist of two main parts :
HIS : Human Interface Station
FCS : Field Control Station
- it is operator station that is used to monitor and control
the process .
FCS is a stand alone unite capable of performing a full
data acquisition control ,and all control function are
executed there with all I/O’s analog & digital signal.
What is the DCS ?

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What is the PESS ?
PESS : Programmable electronic safety system
Vendor : ( Triconex )
which is used for emergency shutdown (ESD) function and
other equipment tripping function .

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MMS : Machine Monitoring system Vendor : ( Bentlt Nevada )
Machine Motoring System , the Bently Nevada system is
used to monitor the vibration of the shaft and the baring
shaft temperature , and to send a signal as hard wire to the
shut down system “ PESS” to trip the machine . Which is
used in Comp package & critical big Pump..etc.
Like :Tank gauging ,Flow computer for custody meter
and Vibration monitoring “ System 1”
Third party Equipment

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What is RIB ?
RIB is Remote Instrument Building
The Remote Instrument Building RIB, which will house, the
DCS controller as FCS ,HIS ,PESS / PLC controller and their
cabinets and all other 3rd party equipment like Tank gauging
,Vibration monitoring , Flow computer , Power supply
distribution panel ,Fire and Gas panel and Uninterruptible
power supplies (UPS ) .

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- DCS filed control station “ FCS “ Cabinets
- Programmable electronic shut down system “PESS Cabinets
- Machine monitoring system “ MMS Cabinets
- Programmable logic control “PLC” Cabinets
- Other equipment such as Tank Gauging , Custody metering
Cabinets
- Air unit
- Fire and gas panel
- All field instruments , wiring signals
- Marshaling panels
-Terminal blocks
-Servers cabinets
What is inside RIB’s

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JB
F TA
HIS
T
B
FCU
FIO
HIS HIS HIS
Control
Room
V-net cable 10
base 5
Optical
converter
Fiber optic
cable
V-net cable 10
base 2
coaxial cable
RIB
FCS
B/N TMR PLC
Copper multi core
shielded cable
FTA or I/O's cable
twisted multi core ,as TEL cable
One pair copper
cable
Serial
communication link
Hard
wire
YNT
FOPP
YNT
FOPP
V-net converter 10 base 5 to 10
base 10
Black
box

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To do down loading ,
Tag equalizing
between the
HIS,s,Trending , and
viewing DCS logic
DCS OPC server
V-net 10 Base 2
cable
Control room YNT
V-Net 10
Base 5
cable
Fiber optic cable
RIB YNT
V-Net cable 10
base 5
FIO
FCS
HIS

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RIB Control Room
Fiber optic
100 MP/S
Fiber optic
1GP/S
2
copper
Fiber
PLC, PESS
PESS – PLC
OPC server
DCS OPC
server
One jacket fiber optic cable
consist of 6 orange cable which
consist of 4 wire
The total is 12 pare wire inside
one jacket

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Conclusions
• Linked execution systems deliver results!
– Reduced direct costs; increased productivity
– Improved traceability; reduced “witch hunt” expense
– Near-theoretical cycle times: customer responsiveness,
reduced WIP inventory
– Greater agility: smaller lot sizes, more premium products in
the mix, happier customers, happier shareholders!
• S95 defines the currency for manufacturing object
and information exchange
– Faster project implementation cycles
– Flexibility to integrate and realign as corporate structures
change

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Status
• ISA95.00.01 & ISA.95.00.02 available
• IEC/ISO 62264-1 available from IEC & ISO
• ISA 95.00.03 in draft
– Still under development in the committee
• World Batch Forum
– Developed XML Schemas for the exchanged
information
• Vendors
– Many currently using ISA-95 models in
development and current products
• Users
– Specifying ISA-95 in their RFPs